Lukas traversing system User Manual

Instruction Manual

30000085 E

Rerailing Equipment

LUKAS traversing system

(Translation of the original instruction manual)

1430000085 EN

Edition 09.2014

Edition 09.2

Content Page

1. Danger classiﬁ cations 4

2. Product safety 5

3. Proper use 8

4. Components and functions 9

4.1 Description 9

4.2 Hydraulic supply to the cylinders 10

5. Connecting the hydraulic equipment 10

5.1 Basic aspects 10

5.2 Coupling the quick-disconnect couplings 11

6. Operation 12

6.1 Setting up the LUKAS traversing system 12

6.2 Start-up 25

6.3 Controlling the LUKAS traversing system with anchor pin 26

6.4 Controlling the DUO traversing cylinder with anchor cylinder 28

7. Dismantling the equipment / deactivation following operation 30

7.1 Hydraulic cylinder 30

7.2 Hoses 30

7.3 Additional components of the traversing system 30

7.4 Hydraulic supply, control and separate load lifting systems 30

8. Maintenance and service 31

9. Repairs 31

9.1 General information 31

9.2 Preventative service 32

9.3 Repairs 33

10. Troubleshooting 36

11. Technical data 38

11.1 Traversing cylinder 38

11.2 Rolling carriage 41

11.3 Rerailing bridges 41

11.4 Connecting rods 42

11.5 Recommended hydraulic ﬂ uids 43

11.6 Operating and storage temperature ranges 43

12. Declaration of conformity 44

13. Notes 45

1. Danger classiﬁ cations

We differentiate between various different categories of safety instructions. The table shown below provides an overview of the assignment of symbols (pictograms) and signal words to the speciﬁ c danger and the possible consequences.

Pictogram

Damage /

injury to

Persons

Property

- NOTE

Key word Deﬁ nition Consequences

DANGER! Immediate danger

WARNING!

CAUTION!

ATTENTION!

Potentially dangerous

situation

Less dangerous

situation

Danger of damage

to property/

environment

Handling tips and

other important/

useful information

and advice

Death or severe

injury

Potential death or

serious injury

Minor or slight

injury

Damage to the

equipment,

damage to the

environment,

damage to

surroundings

No injury/damage

to persons/

environment/

device

Wear a helmet with a face guard

Wear protective gloves

Wear safety shoes

Proper recycling

Protect the environment

Read and follow the operating instructions

2. Product safety

LUKAS products are developed and manufactured to ensure the best performance and quality when used as intended. The safety of the operator is the most important consideration in product design. Furthermore, the operating instructions are intended to help in using LUKAS products safely. The generally applicable legal and other binding regulations pertaining to the prevention of accidents and protection of the environment apply and are to be complied with in addition to the operating instructions. The equipment must only be operated by persons with appropriate training in the safety aspects of such equipment – otherwise, there is a danger of injury. We would like to point out to all users that they should read carefully the operating instructions and the instructions contained therein before they use the equipment, and that they should carefully follow such. We further recommend you have a qualiﬁ ed trainer show you how to use the product.

CAUTION!

The operating instructions for the hoses, the accessories and the connected devices must also be heeded!

Even if you have already received instruction on how to use the equipment, you should still read through the following safety instructions again.

WARNING / CAUTION!

Ensure that the accessories and connected equipment are suitable for the maximum operating pressure!

Please ensure that no body parts or clothing are caught between the visibly moving parts (e.g. piston guard plate and cylinder).

Wear protective clothing, a safety helmet with visor, protective footwear and gloves

Immediately report any changes that occur (including changes in operating behaviour) to the appropriate persons/departments! If necessary, the equipment is to be shut down immediately and secured!

Working under suspended loads is not permitted where such loads are being lifted only using hydraulic devices. If working under suspended loads is unavoidable, suitable mechanical props are also required.

Inspect the device before and after use for visible defects or damage.

Check all lines, hoses and screwed connections for leaks and externally visible damage, and repair immediately! Escaping hydraulic ﬂ uid can cause injuries and ﬁ res.

In the event of malfunctions, immediately deactivate the equipment and secure it. Repair the fault immediately.

Do not carry out any changes (additions or conversions) to the equipment without obtaining the approval of LUKAS beforehand.

Observe all safety and danger information on the device and in the operating instructions.

Any mode of operation which compromises the safety and/ or stability of the device is forbidden!

Safety devices must never be disabled!

Make sure before switching on/starting up the device and during its operation, that this will put no one in danger.

When working close to live components and cables, suitable measures must be taken to avoid current transfers or high-voltage transfers to the equipment.

All safety and danger information on the device must always be complete and in a legible condition.

Observe all intervals for recurring tests and/or inspections that are prescribed or stated in the operating instructions.

The maximum permitted operating pressure noted on the equipment must not be exceeded.

Only genuine LUKAS accessories and spare parts are to be used for repairs.

Please ensure that, when working with this equipment or during transportation of such, you don’t get caught up in the looped hoses and trip.

The build-up of static charge and therefore possible sparking must be avoided when handling the device.

The equipment is ﬁ lled with hydraulic ﬂ uid. This hydraulic ﬂ uid can be detrimental to health if it is swallowed or its vapour is inhaled. Direct contact with the skin must be avoided for the same reason. Also, when handling hydraulic ﬂ uid, note that it can negatively affect biological systems.

When working with or storing the equipment, ensure that the function and the safety of the equipment are not impaired by the effects of severe external temperatures or that the equipment is damaged in any way. Please note that the equipment can also heat up over a long period of use.

Make sure there is adequate lighting while working.

Always keep these operating instructions easily accessible at the place of operation.

In addition to the safety instructions in this operating manual, all generally applicable, statutory and otherwise binding national and international regulations for accident prevention must be heeded and disseminated!

Before transporting the equipment, always ensure that the accessories are positioned in such a way that they cannot cause an accident.

Dispose properly of all disassembled parts, oil and left-over ﬂ uid, as well as packaging materials.

WARNING / CAUTION / ATTENTION!

The device is intended exclusively for the purpose stated in the operating instructions (see chapter "Proper Use"). Any other use is not considered to be as intended. The

manufacturer/supplier is not liable for any damage resulting from use not as intended. The user bears sole responsibility for such use. Proper use includes observance of the operating instructions and compliance with the inspection and maintenance conditions.

Never work in a fatigued or intoxicated state!

3. Proper use

The components of the LUKAS traversing system are especially designed for re-railing technology . They are used for rerailing of rail-bound vehicles. Derailed vehicles can be lifted up and moved at right angles to the track. The accessories necessary for the particular application, such as base plate, multistage sets etc., must be used during each deployment.

When carrying out any work, use the traversing system described here and the connected hoses and equipment to ensure that you yourself, the involved and uninvolved persons in the proximity of the work and objects in closer proximity during the lifting and traversing process are not endangered.

ATTENTION!

Watch out vigilantly for any leaks in order to avoid threats to the environment.

The LUKAS traversing system consists of:

- Item 1 Rerailing bridge

- Item 2 DUO traversing unit

- Item 3 Rolling carriage

- Item 4 Adjustable connecting rods

NOTE:

In order to be able to lift vehicles and move them, either lifted up or placed on the traversing system, you need to use suitable lifting equipment (e.g. LUKAS HP cylinders) and their accessories.

4. Components and functions

4.1 Description

4.1.1 Rerailing bridge

The rerailing bridge is placed at right angles over the tracks and provides the support and moving surface for the LUKAS rolling carriages and the DUO traversing unit. If one bridge is not long enough, a second bridge can be screwed on by means of joining elements. The integrated anchor cylinder locates as a locking pin in the arresting openings in the top of the rerailing bridge. The rerailing bridges are transported using the pull-out handles mounted at the sides.

4.1.2 Rolling carriages

The LUKAS rolling carriages are designed to carry heavy loads. The special rollers on the bottom of the rolling carriage mean that it can be moved in the rolling direction by hand or using traversing cylinders. The rolling carriages are specially adapted to LUKAS rerailing bridges and provide optimum movement for the load. The top slide plate on the rolling carriage is placed on the carriage and can be rotated and moved at right angles to the rolling direction. The movements arising during lifting and traversing are thus given more room. Tipping of the rolling carriage or a cylinder mounted on it is prevented if positioned correctly.

4.1.3 DUO traversing unit

The DUO traversing unit is designed to move the LUKAS rolling carriages on the rerailing bridges. The traversing cylinder is a double-acting hydraulic cylinder whose piston rod end is hooked into the ﬁ xing point provided on the rolling carriage. This makes it possible to move the rolling carriage in the retraction and extension directions of the traversing cylinder. The anchor cylinder serves as the locking pin.

The DUO traversing unit is available in two different variants.

1) One variant has a ﬁ xed pin which locks the traversing cylinder in the ﬁ xing points on the LUKAS rerailing bridge.

2) The other variant instead has an integrated anchor cylinder that can be retracted and extended hydraulically. In addition, this variant has lateral guide plates on the anchor cylinder to provide stabilisation. The advantage of the version with an anchor cylinder is that the cylinder can be reset without the user having to enter the danger area. In the unloaded condition, this cylinder is always extended, so that, in the event of a loss of pressure in the hydraulic system, there is still an anchoring in the rerailing bridge. When pressurised, the anchor cylinder retracts and allows the traversing cylinder to move by extending or retracting.

A prerequisite for the operation of both variants is that the rerailing bridge is aligned horizontally and that the load is lifted in such a way that there is no danger of the load suspended in this way rolling away to the side.

4.1.4 Connecting rods

The connecting rods are used if a load is to be lifted at two or more points and then is to be moved, at the same time, using rolling carriages in one direction. The connecting rods are always used in pairs and connect the rolling carriages together. The connecting rods have a coarse and a ﬁ ne setting facility in order to be able to set them precisely to the distance between the individual lifting points.

4.2 Hydraulic supply to the cylinders

Only the speciﬁ ed LUKAS hydraulic power packs (motor pumps) or suitable LUKAS hand pumps can be used to drive the equipment. If the pump unit is a different make, you must make sure that it complies with LUKAS speciﬁ cations, otherwise potential dangers may occur which are not the responsibility of LUKAS. Ensure in particular that the maximum permissible operating pressure for the connected LUKAS equipment is not exceeded.

NOTE:

Before you use pumps from a different manufacturer, you must contact LUKAS or an authorised dealer.

The connection between the hydraulic power pack (pump unit) or hand pump and the hydraulic cylinders is by hoses.

5. Connecting the hydraulic equipment

5.1 Basic aspects

On the double-acting hydraulically-actuated working equipment, there is, on the pressure supply side (with cylinders: on the cylinder base side) a plug coupling nipple

and on the return side (with cylinders: on the piston rod side) a plug connection sleeve; and these are connected to the control unit by pairs of hose extensions.

A plug connection nipple is provided on the single-acting hydraulically-actuated working equipment; and this is connected to the pump unit or control unit via hose extension.

If you are using single-acting cylinders (particularly of a previous type), LUKAS recommends that you contact LUKAS or an authorised dealer. Using single-acting locking-cylinders a

sticker (accessory order no. 43010073) is available to simplify operation. For unlocking the control leaver must be pulled in direction of the the operator.

The hose extension pairs are supplied in various lengths. The individual hoses can, if required, also be marked with coloured snap rings to make it easier to allocate the hoses.

(For speciﬁ c details, please consult the LUKAS range of accessories or contact your LUKAS dealer.)

WARNING / CAUTION / ATTENTION! Prior to connecting the devices, ensure that all the components

being used are suitable for the maximum operating pressure of the pump unit! In case of doubt you must consult LUKAS

directly!

5.2 Coupling the quick-disconnect couplings

The device is connected to the hydraulic pump without risk of misconnection using monocoupling halves (female and male coupling).

Before coupling, remove dust caps and then pull back and hold the locking sleeve of the female coupling half (position X). Connect the male and female couplings and release the locking sleeve. Then turn the locking sleeve to position Y. The connection has been made and locked. Uncoupling is done in the reverse order. Coupling of the devices is only possible, when the hoses are depressurised. For dust protection, the supplied dust caps must be reﬁ tted.

ATTENTION!

Always connect the return line ﬁ rst and then the supply line!

NOTE:

Coupling of the devices is only possible, when the hoses are depressurised.

For dust protection, the supplied dust caps must be reﬁ tted.

WARNING / CAUTION / ATTENTION! Some quick-disconnect couplings have special functions.Therefore, you must

not unscrew them from the hoses or swap them over!

6. Operation

6.1 Setting up the LUKAS traversing system

6.1.1 General

The LUKAS traversing system consists of several individual components. Appropriate combination of the individual components can be used to set up various different total systems. With some of these overall systems, not all the individual components are required, and on others you will need several of the individual components. In addition to the individual components of the LUKAS traversing system, suitable hydraulic cylinders will be required for lifting the load and at least one suitable hydraulic power pack or a suitable hand pump will be needed to provide the pressure.

6.1.2 Basic work required for setting up the traversing system

CAUTION / ATTENTION!

Prior to setting up the individual components of the LUKAS traversing system, the load to be lifted must be secured against slipping as prescribed in the respective applicable guidelines and regulations. The relevant rerailing concepts of the vehicle manufacturer must be observed.

Before setting up the traversing system, check the individual components for visible damage.

You must always take into account the following when setting up the components of the traversing system:

- Please ensure that the load is applied centrally to the piston rod or rolling carriage plate.

NOTE:

Select the more favourable load grip point in order to guarantee maximum safety!

Position the cylinder/rolling carriage underneath the centre of gravity of the load, such that the load cannot tip over during lifting and endanger the operating staff or the equipment being used. The load should always act centrally on the piston surface or the surface of the rolling carriage plate. Avoid lateral forces acting on the cylinder! Frequently it is not possible to apply the load on the full cylinder surface. LUKAS also

Load

WRONG RIGHT

Load

recommends the use of suitable piston guard plates for this reason, as otherwise there is a risk of damage to the piston rod or the cylinder. A convex piston guard plate distributes the load evenly over the piston area again. If several cylinders/rolling carriages are used simultaneously, the load should be distributed as evenly as possible over all cylinders/rolling carriages.

Load

WRONG

The following must always be observed when installing the cylinders:

Load share 1

Load proportion 1 < Load proportion 2

WRONG RIGHT

- non-slip and even ground, so that the entire base area of the cylinder is in contact with the ground. If there is any doubt as to the load-bearing capacity of the ground, suitable wooden or metal underplates (blocks) must be used to increase the contact area.

- The area of support must be a continuous level surface (not a grating, gravel etc.)

Load share 2

Load share 1

Load proportion 1 = Load proportion 2

Load

RIGHT

Load share 2

WRONG

ATTENTION!

Hydraulic ﬂ uids may produce a lubricating ﬁ lm on the ground!

- Never place cylinders on a yielding underplate

- Never use cylinders without a piston guard plate, in order to avoid damage to the piston

RIGHT

and achieve safe power introduction

- Please ensure that the load is applied centrally to the piston rod.

- Stability and load application is improved if you use load distribution plates. Distribution plates permit an angle of inclination of 5 °.

ATTENTION!

Observe the permissible angle of inclination when lifting the vehicle!

6.1.3 Setting up the rerailing bridges

The bridge is placed across the tracks and carefully supported by wooden planks. Please observe that:

- The rerailing bridge and the supporting wooden beam packers are on a non-deﬂ ecting

ﬁ xed subsurface.

CAUTION / ATTENTION!

When using wooden underplates, care must be taken that particularly hard wood without damage is used, so that the underplate cannot crack. Strapping additional pieces of wood together with metal bands is not sufﬁ cient!

- The maximum load of the bridge is not exceeded. See the following table.

Bridge height Support width Max. load

[mm] [m] [kN]

[in.] [ft.] [lbs.]

85 0 350

3.35 0 787000

140 0 1000

5.51 0 225000

184 0 1200

7.24 0 270000

* *

160

3.28 13500

1.43 50

4.69 11200

* *

1 500

3.28 112000

1.43 400

4.69 90000

* *

1 900

3.28 202000

1.43 650

4.69 146000

* completely packed up

- The maximum load of the bridge connecting elements (optional) is not exceeded:

Bridge height Support width Max. load

[mm] [m] [kN]

[in.] [ft.] [lbs.]

85 1 20

3.35 3.28 4500

140 1 200

5.51 3.28 45000

184 1 300

7.24 3.28 68000

- the bridge is horizontally aligned:

The angle of the bridge may not exceed 3°. If one bridge is not long enough, a second bridge can be screwed on by means of joining elements. This done by placing the ends of the rerailing bridges together and bolting them together using ﬂ at steel plates, bolts, washers and nuts (as shown in the illustration below). You must ensure that the top running surfaces of the rerailing bridges are not offset to each other axially, since otherwise proper movement cannot be guaranteed and/or this can lead to damage to the individual components.

6.1.4 Setting up the rolling carriages

The rolling carriages are mounted on the rerailing bridges in such a way that the rollers of the rolling carriages can move along the rerailing bridges. The guides on the rolling carriages prevent it from slipping off the rerailing bridge to the side.

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